Method of forming molds for casting purposes.



UNITED STATES PATENT OFFICE...

JOSEPH G. WEYER, OF PROVIDENCE, RHODE ISLAND.

' METHOD OF FORMING MOLDS FOR CASTING PURPOSES.

Patented Feb. 27, 1906.

Application filed June 26,1905. Serial No. 267,321.

To all whom it may concern:

Be it known that I, Josnrn G. WEYER, a citizen of the United. States, residing at the city of Providence, in the county of Providence and State of Rhode Island, have 1nvented certain new and useful Improvements in Methods of Making or Formin Moldsfor Casting ljurposes, of which the 0 lowmg 1s a specification. r

This invention relates to the method of making or forming molds for casting purposes, and has for its object the production of a mold by means of which the most delicate outlines and designs may be reproduced from the pattern and brought out in the casting. A mold for this purpose must be constructed in such a manner as.to stand the heat necessar for drying it and also the heat of the me ted metals poured into it without crackin or crumbhng. At the same time the mo (1 must be porous enou h to ad-' mit a free escape of the gases usual y generated by fluid metals. v

My invention consists, essentially, of a method of making a' mold composed of calcined plaster of paris and finelyscreened coal-ashes mixed together in given proportions.

In forming my mold I first mix plaster-ofparis with water to about the consistency of a thick creamy substance. Then the finelysifted ashes are mixed with water to about the same consistency, and these two substances are then mixed together in about equal proportions, one half of the plaster-ofparis and one half of the ashes and Well stirred to form a uniform mass. The material is then poured around the pattern, formthen the other.

mg a mold 1n two halves in substantially the kn same manner as plaster molds are formed, first one half of the mold being made and When the mixture is poured around the first half, it is allowed to set for fifteen or twent minutes without heat, after which the mold is turned over and the second half is formed in a similar manner and the mold again sets for about. the same length of time, after'which the pattern may be removed and the mold gated and placed in, the drying-oven, Where it is exposed to a moderate heat-say 250 to 300 Fahrenheit-for about four or five hours, more or less, so as to evaporate the greater portion of the moisture and render the molds practically dry. In forming molds by some methods the same has to be exposed to heat for about twentyfour hours before the pattern can be removed therefrom. It is obvious that by such a method the formin pattern would be slow and tedious Work and that asthe pattern has also to be exposed to great heat only metal patterns could be used, while with my improved method the attern only remains in the mold about onealf hour in all. Hence many molds may be made in one day. Then again a most important feature of my method is that by not bemg. obliged to su mit my pattern to heat I can use models formed of wax, plaster-ofparis, wood, cla or any other suitable material which wi 1 work equally as well as metal.

Bciy the use of ashes mixed pro uce a mold that is very orous as compared with molds formed entlrely of plaster or of plaster mixed with asbestos or other fibrous material. A mold constructed of plaster and ashes in the pro ortions named on account of its porous qua ities need not be heated to so high a degree in order to evaporate the moisture and renderit dry preparatory to receiving the molten metal. This composi tion also forms a mold into which I can pour the metal the same as in a dry-sand mold. Another advantage is that m mold dries quicker and not requiring to be eated so hot it cools quicker. saved in preparing these molds over the time taken to prepare one of plaster alone or plaster and asbestos combined.

Another advantage gained frommy improved mold is that on account of its porous nature brass may be poured into it and perfect castings obtained therefrom. As is well own by those skilled in the art of molding, brass requires a very porous mold to carry off the excessive amount of gases generated therefrom while in a molten state. Then again, the expense of the material in my mold is reduced to a minimum, as both plaster-of paris and coal-ashes are very inexpensive, especially the coal-ashes, which is a waste product. i

A long practical experience. in molding has established the fact that a mold constructed in the manner above described will produce the finest castings that is possible to be taken fromv a mold, and this result maybe produced by simply pouring into this mold the same as in a dry-sand mold-and positively does not require mechanical pressure in order to produce good castings. In fact, some of with plaster I Therefore several hours are the castings I have taken from my molds have been so thin and sharp and perfect in every detail that they have been pronounced by experts to be equal to those that have been stuck up by a die.

In my mold properly constructed of the required ingredients of plaster-of-paris and ashes I can cast metals that melt as low as 600 or 700 Fahrenheit such as zinc, britannia, and the like-or I can cast equally as well the harder metals that melt at from-1,000 to 2 ,000", such as gold, silver, brass, and the like.

The material of my molds is of sufficient strength to permit the use of elastic-rubber patterns having many deep and fine undercuts in their designs. The elastic patterns can be drawn from a mold made of my com osition without breaking away the deep un ercuts in the design. Molds made of my composition of plaster-of-paris and ashes can be usedfor casting metals in them with most satisfactory results either, by pressure applied to the fluid metal to force it into the molds or by vmeans of simply pouring the metal into the mold, as is done ordinarily in using sand or loam molds.

In order to give an idea of the novelt and utility of my invention, I may state tl iat it has been the aim of founders and artisans to use molds made of plaster for castin metals, especially brass, bronze, German an sterling silver, gold, &c., because the most delicate outlines and design of a given pattern can be more accurately and sharply reproduced in a laster mold than in a mold of sand or loam.

etals meltin at a low degree of heat are cast in pure p aster molds. Such metals as type metal, tin, britannia, and zinc have been cast in plaster molds with success, but the metal has to be forced into the molds by mechanical pressure. Sterling silver and some low-melting brass compositions have been cast in plaster molds by pressure; but theresults with these metals were never satisfactory or practical even though cast under pressure. The molds could. not with stand the heat necessary to dry them perfectly and effectually. Consequently they cracked when the red-hot metal was injected. They also became soft and the pressure on the metal caused it to penetrate into the mold, producing a rough casting and obliterating my mixture of plaster-of-paris and ashes, as specified, I produce an extremely strong mold with a very fine smooth face and one which will withstand the heat and reproduce practically as fine a casting as a mold made out of plaster alone. The combination of the ashes mixed with the plaster in the required proportions gives to it all of the necessary qualifications for withstanding the heat and carrying off the gases to finest quality of castings.

Having thus described my invention, what I claim as new, and desire to obtain by Letters Patent, is

1. The method of making molds forcastall fine outlines and design; but by the use of produce the ing purposes, consisting in mixing plaster-ofparis with water and finely-sifted coal-ashes with water, and then mixing these two substances together, forming said mixture into a mold around a suitable pattern, and finally subjecting the same to a moderate uniform heat for a period not exceeding five hours and then permitting the mold to cool.

2. The method of-making molds for castingl purposes, consisting in mixing equal quantities of plaster-of-paris and finely-sifted coal-ashes, said ingredients having been previously mixed with water, pouring said mixture around a pattern to form portions of the mold, which portions are allowed to set and dry without heat, removing said pattern when the mold is completed, and finally subj ecting the substantially dry mold to a moderate uniform heat for a period not exceeding five1 hours and then permitting the mold to coo In testimony whereof I afiix my signature in presence of two witnesses.

JOSEPH G. WEYER. 

